Leader tape, magnetic tape cartridge, and magnetic recording and reproduction method

ABSTRACT

A leader tape has, on at least one face of a support, a coating layer that contains a powder and a binder, which is characterized in that the center line average roughness (Ra) of at least one face of the leader tape is from 10 to 60 nm, the leader tape is used in a magnetic recording and reproduction device where the line recording density is at least 100 kfci, and the difference between the recording track width and the reproduction track width is from 0 to 16 μm.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a leader tape, to a magnetic tape cartridge in which the cartridge case rotatably houses a reel with a magnetic tape wound up therearound along with the leader tape bonded thereto, and to a magnetic recording and reproduction method.

2. Description of the Invention

As magnetic tape cartridges used as recording media for external memory devices for computers and others, heretofore known are those of a type where a magnetic tape is wound up around one or more reels rotatably housed in the cartridge case. Since the magnetic tapes are used for data storage for computers and others and since important information is recorded therein, the cartridges are specifically so designed that they are free from a trouble of tape jamming and that a magnetic tape is not carelessly led out of them.

In a single reel-type cartridge, a leader member such as a leader pin or a leader block is fitted to the top end of the magnetic tape, via which the magnetic tape is led out of the cartridge; or a leader tape is bonded thereto, which is formed of a relatively hard plastic material and which has engage holes formed at the top end of the tape. For the cartridge of the type, a drive device is so constructed that the magnetic tape therein could be loaded/unloaded (draw out/wind up) while the leader member or the leader tape top end is held by the holder member on the side of a recording and reproduction device.

In the loading/unloading process as above where the magnetic tape is drawn out toward the side of the magnetic recording and reproduction device and its top end is wound up around the drive reel in the device, the top end of the magnetic tape is contacted with the tape guide and the magnetic head disposed along the tape-running route, while not accurately positioned relative to them, and in that condition, it is pulled and is therefore readily damaged. Accordingly, it is desirable that the top end of the magnetic tape is reinforced.

In addition, the reinforcement is also desirable in order to prevent the leader block level difference occurring in the drive reel from being embossed onto a data-recording magnetic tape to increase the dropouts in the tape. For this, a leader tape having a higher strength than that of a magnetic tape is bonded to the top end of the magnetic tape (e.g., see JP-A-2001-110164).

With the recent increase in the capacity of magnetic tape cartridges, the recording density of magnetic tapes is increasing, and drive makers are now toward increasing the in-plane recording density of magnetic tapes by reducing the recording wavelength so as to increase the recording density in the machine direction of tapes and further by reducing the recording track width so as to increase the recording density in the lateral direction thereof. With the increase in the recording density, the influence of the spacing between the magnetic layer and the magnetic head increases, and therefore, when magnetic tapes are deformed, then they cause dropouts and significantly increase error rates.

The leader block mentioned above is so designed that it may be housed in the recess formed in the core of a take-up reel, and when housed therein, a part of the leader block forms a part of the arc face of the core.

This is graphically illustrated. As in FIG. 4A, a leader block 40 is fitted into the recess 42 formed along the radial direction of the core 41, and, for example, in this condition, the end face 40 a of the leader block 40 forms a part of the take-up face of the core 41. As illustrated, the end face 40 a of the leader block 40 is curved like an arc in correspondence to the outer peripheral face of the core 41, in order to smoothly wind up the magnetic tape MT around it.

However, in such a related art tape drive, the end face 40 a may protrude above the core 41, as in FIG. 4B, depending on the dimensional accuracy of the leader block 40 that constitutes a part of the take-up face, and it may form an unacceptable level difference in the take-up face of the core 41.

The level difference may cause folding or deformation of the leader tape LT, and, as in FIG. 4C, the folding and the deformation occur similarly also in the part of the magnetic tape MT which is wound up as the subsequent layers and which is to be a substantial recording region (this may be referred to as “leader block embossment”). The leader block embossment may cause a problem in that a suitable distance between the tape and the recording/reproducing head could not be ensured in the process of information recording/reproduction, and it may therefore cause recording failure and information loss.

If the time for which the tape is kept wound up around a take-up reel is short, then the leader block embossment would not cause the problems as above, but when the magnetic tape MT is kept wound up around the take-up reel and left as such for long, then the magnetic tape MT may often have a regular leader block embossment on the surface thereof, at a pitch of nearly the circumference length of the core 41.

Accordingly, it has become necessary to improve the leader tape. This phenomenon is more remarkable in a system where the line recording density is smaller. In a system where the difference between the recording track width and there production track width is over 17 μm, tape deformation to cause track shifting by a few μm or so may not result in the increase in dropouts, since the recording track width is much broader than the reproduction track width and therefore the tape may run on the recording track even after such a little tape deformation. However, in a magnetic recording and reproduction device where the difference between the recording track width and the reproduction track width is at most 16 μm, the track shifting owing to tape deformation becomes remarkable; and in a magnetic recording and reproduction device where the difference is at most 10 μm, it is substantially remarkable.

SUMMARY OF THE INVENTION

An object of the invention is to provide a leader tape not so much troubled by the increase in dropouts to be caused by embossment of a drive reel or a leader block onto it during long-term storage or high-temperature running in or through a magnetic tape cartridge for magnetic recording and reproduction devices for high-density recording at high line recording density and high track density; and to provide a magnetic tape cartridge, and a magnetic recording and reproduction method.

The object of the invention can be attained by the following means:

1) A leader tape having, on at least one face of a support, a coating layer that contains a powder and a binder, which is characterized in that the center line average roughness (Ra) of at least one face of the leader tape is from 10 to 60 nm, the leader tape is used in a magnetic recording and reproduction device where the line recording density is at least 100 kfci, and the difference between the recording track width and the reproduction track width is from 0 to 16 μm.

2) The leader tape of above 1), which has a thickness of from 5 to 20 μm.

3) A magnetic tape cartridge where a magnetic tape is wound up around one or more reels rotatably housed in the cartridge case, in which the leader tape that is bonded to the top end of the magnetic tape and is let out toward a magnetic recording and reproduction device while leading the magnetic tape is the leader tape of above 1) or 2).

4) A magnetic recording and reproduction method, which comprises using the magnetic tape cartridge of above 3) in the magnetic recording and reproduction device in above 1).

The leader tape of the invention is designed to have a specifically-defined surface roughness, and therefore, when it is wound up, a suitable distance may be formed between the faces of the wound tape. The remarkable advantages of the leader tape of the type are that, since the pressure to it may be relieved, a leader block and others are prevented from being embossed to magnetic tapes; and even when the line recording density is increased and the track width is narrowed in magnetic recording and reproduction devices, the leader tape may effectively prevent the increase in dropouts and error rates that may be caused by the leader block embossment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a constitutional view conceptually showing a magnetic recording and reproduction device of one embodiment of the invention.

FIG. 2 is a perspective exploded view showing the magnetic tape cartridge used in the magnetic recording and reproduction device.

FIG. 3A is a perspective view of the drive reel used in the magnetic recording and reproduction device; FIG. 3B is a partly-enlarged cross-sectional view of FIG. 3A cut along the IIIB-IIIB line.

FIGS. 4A to 4C are explanatory views of a related art.

DETAILED DESCRIPTION OF THE INVENTION

The center line average roughness (Ra) of at least one face of the leader tape of the invention is from 10 to 60 nm.

“Ra” as referred to herein means a value measured with a photointerference surface roughness meter (WYKO's HD-2000) under the condition mentioned below.

Objective lens: 50-power, intermediate lens: 0.5-power, and detection range: 242 μm×184 μm; and after cylindrical correction and inclination correction, Ra is calculated.

The leader tape of the invention is used in a magnetic recording and reproduction device in which the line recording density is at least 100 kfci and the difference between the recording track width and the reproduction track width is from 0 to 16 μm.

Not specifically defined, the magnetic recording and reproduction device may be any one that comprises a magnetic tape cartridge and a magnetic tape drive.

Not also specifically defined, the magnetic tape cartridge may be any one in which a magnetic tape with the leader tape of the invention bonded thereto is wound up around one or more reels rotatably housed in the cartridge case. The invention produces better results when applied to single reel devices.

The leader tape of the invention may be bonded to the top end of a magnetic tape on and from which signals are recorded and reproduced, by attaching a known splicing tape thereto in such a manner that one end of the leader tape is butt-jointed with the top end of the magnetic tape. The other end of the leader tape is provided with an engaging member such as leader pin, and this is used for fixing the leader tape to the drive reel of a magnetic recording and reproduction device.

The magnetic recording and reproduction method of the invention is characterized in that the magnetic tape cartridge of the invention is used in the magnetic recording and reproduction device where the leader tape of the invention is used, and it enables recording and reproduction under the condition where the line recording density of the magnetic tape to which the leader tape is bonded is at least 100 kfci (preferably at least 130 kfci, more preferably at least 150 kfci) and the difference between the recording track width (preferably at most 28 μm, more preferably at most 16 μm) and the reproduction track width (preferably at most 13 μm, more preferably at most 8 μm) is from 0 to 16 μm (preferably from 4 to 16 μm, more preferably from 4 to 10 μm).

The magnetic recording and reproduction method of the invention prevents track shifting and enables stable recording and reproduction even when the recording track width is narrow and the difference between the recording track width and the reproduction track width is small as in the method.

The recording and reproduction device in which recording and reproduction is attained at the above-mentioned track width is not specifically defined, for which are usable any known magnetic recording and reproduction devices equipped with recording/reproduction heads.

The magnetic head for use in the invention is preferably an inductive head for recording, and an MR head for reproduction.

The invention is described in more detail hereinunder.

[Leader Tape]

The coating layer formed on the support essentially comprises a dispersion of a fine inorganic powder in a binder. The fine inorganic powder may be a non-magnetic powder or a magnetic powder. The coating layer may be single-layered or multi-layered. The coating layer is formed on at least one of the face of the support that is to be in contact with a magnetic head, or the opposite face thereto.

The object of the coating layer is for optionally giving some additional function to the support. For example, abrasive particles are added to the face of the support that is to be in contact with a magnetic head so as to make the resulting tape have a cleaning effect; conductive particles are added thereto so as to make the resulting tape have an antistatic function; or a magnetic substance is added thereto in order to record magnetic signals on the resulting tape.

The coating layer may further contains a lubricant by which the friction factor of the layer may be controlled. Preferably, the coating layer is so designed that the same magnetic layer as that in the data tape to be bonded to the leader tape, or a non-magnetic tape each alone, or a double layer that comprises such a magnetic layer formed on a non-magnetic layer is formed on the side of the support that is to be in contact with a magnetic head and a back layer of essentially carbon black is formed on the opposite side thereto.

Preferably, the overall thickness of the leader tape is from 5 to 20 μm, more preferably from 8 to 18 μm.

Regarding the thickness of the coating layer, the single layer or a total of multiple layers is preferably from 0.1 to 5.0 μm, more preferably from 0.5 to 3.0 μm. Also preferably, the thickness of the support is from 3 to 17 μm, more preferably from 6 to 17 μm.

The center line average roughness (Ra) of at least one surface of the leader tape is from 10 to 60 nm, preferably from 15 to 45 μm. This produces a cushion effect when the tape is wound up around a reel, and therefore prevents leader block embossment to the tape. The surface roughness Ra of the leader tape may be the same or may differ between the back face and the front face there of. The surface roughness may be controlled in various methods. For example, the roughness of the support, the thickness of the coating layer, the particle size of the inorganic particles to be sued in the coating layer and the calendering condition may be varied. When the surface roughness of the leader tape is controlled by the roughness of the support, then the roughness of the support may be from 5 to 80 nm, preferably from 10 to 65 nm. The inorganic powder to be in the coating layer may have a mean particle size of from 0.02 to 1 μm, preferably from 0.05 to 0.6 μm. Its shape may be any of granular, needle-like, tabular or cubic ones.

Preferably, the surface resistivity of the leader tape is at most 10¹⁰ Ω/sq, more preferably at most 10⁹ Ω/sq. Thus controlled, the leader tape is prevented from being statistically charged and is prevented from being damaged by static charges of magnetic heads, whereby its reliability is increased. In addition, the strength of the leader tape is basically higher than that of the magnetic tape which is bonded to the leader tape, and when the magnetic tape cartridge having therein the two tapes bonded to each other is driven in a magnetic recording and reproduction device in which the tapes are repeatedly loaded/unloaded, then the durability of the leader tape is kept high.

For controlling the surface resistivity of the leader tape to fall within the predetermined range, for example, a conductive powder such as carbon black may be added to at least one layer of the lower layer, the upper layer and the back layer of the tape. For example, from 1 to 20 parts by weight of carbon black may be added to 100 parts by weight of the binder in each layer.

Preferably, the leader tape is a magnetic tape that comprises a non-magnetic layer containing an inorganic powder and a binder as the lower layer and a magnetic layer containing a ferromagnetic powder and a binder as the upper layer, and has a back layer formed on the opposite side thereto.

The leader tape that is the magnetic tape as above is described in detail hereinunder.

(Magnetic Layer)

<Binder in Magnetic Layer and Non-Magnetic Layer>

The binder to be used in the magnetic layer and the non-magnetic layer may be any of known thermoplastic resins, thermosetting resins, reactive resins and their mixtures. The thermoplastic resin may have a glass transition point falling between −100 and 150° C., a number-average molecular weight falling between 1000 and 200000, preferably between 10000 and 100000, and a degree of polymerization falling between about 50 and 1000 or so.

Examples of the resin of the type are polymers or copolymers comprising constitutive units of vinyl chloride, vinyl acetate, vinyl alcohol, maleicacid, acrylic acid, acrylate, vinylidene chloride, acrylonitrile, methacrylic acid, methacrylate, styrene, butadiene, ethylene, vinyl butyral, vinyl acetal, vinyl ether and the like; and polyurethane resins, and various rubber-type resins. The thermosetting resin and the reactive resin include, for example, phenolic resins, epoxy resins, polyurethane-curable resins, urea resins, melamine resins, alkyd resins, acrylic reactive resins, formaldehyde resins, silicone resins, epoxy-polyamide resins, mixtures of polyester resins and isocyanate prepolymers, mixtures of polyester-polyols and polyisocyanates, and mixtures of polyurethanes and polyisocyanates. These resins are described in detail in Plastic Handbook (published by Asakura Shoten). In addition, any known electron ray-curable resin may be used in each layer. Its examples and its production methods are described in JP-A 62-256219.

The above-mentioned resins may be used herein either singly or as combined. Preferably, at least one selected from polyvinyl chloride resins, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-vinyl alcohol copolymers and vinyl chloride-vinyl acetate-maleic anhydride copolymers is combined with a polyurethane resin and a polyisocyanate for use in the invention.

The polyurethane resin may have any known structure of polyester-polyurethane, polyether-polyurethane, polyether-polyester-polyurethane, polycarbonate-polyurethane, polyester-polycarbonate-polyurethane, and polycaprolactone-polyurethane. Optionally but preferably, all these binders have at least one polar group selected from COOM, SO₃M, OSO₃M, P═O(OM)₂, O—P═O(OM)₂ (in these, M represents a hydrogen atom or an alkali metal base), OH, N(R)₂, N+(R)₃ (where R represents a hydrocarbon group), epoxy group, SN and CN, introduced thereinto through copolymerization or addition reaction, in order that the binders may realize further better dispersibility and durability. The amount of the polar group in the binders may be from 10⁻¹ to 10⁻⁸ mol/g, preferably from 10⁻² to 10⁻⁶ mol/g.

Preferably, the number of the hydroxyl groups to be in the polyurethane resin is from 3 to 20 in one molecule, more preferably from 4 or 5 in one molecule. If the number is smaller than 3 in one molecule, then the reactivity of the resin with a polyisocyanate curing agent may lower and therefore the film strength and the durability may lower. If, however, the number is larger than 20, then the solubility and the dispersibility in solvent of the resin may lower. For controlling the content of the hydroxyl groups in the polyurethane resin, a compound having at least three functional hydroxyl groups may be used in producing the polyurethane resin. Concretely, there are mentioned trimethylolethane, trimethylolpropane, trimellitic anhydride, glycerin, pentaerythritol, hexanetriol; as well as branched polyesters and polyether-esters having 3 or more functional hydroxyl groups that are obtained from a dibasic starting from a polyester-polyol described in JP-B 6-64726 and the compound serving as a glycol component. Preferred for use herein are tri-functional compounds. Tetra- or more multi-functional compounds may readily gel in the reaction step.

The polyisocyanates usable herein are, for example, isocyanates such as tolylene diisocyanate, 4,4′-diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate, xylylene diisocyanate, naphthylene-1,5-diisocyanate, o-toluidine diisocyanate, isophorone diisocyanate, triphenylmethane triisocyanate; products of these isocyanates with polyalcohols; and polyisocyanates produced through condensation of these isocyanates.

The amount of the binder to be in the magnetic layer and the non-magnetic layer may be generally from 5 to 50% by weight, preferably from 10 to 30% by weight of the ferromagnetic powder in the magnetic layer or of the non-magnetic inorganic powder in the non-magnetic layer. When a vinyl chloride-based rein is used, its amount may be from 5 to 30% by weight and when a polyurethane resin is used, its amount may be from 2 to 20% by weight; and the amount of the polyisocyanate to be combined with these is preferably from 2 to 20% by weight. For example, however, when head corrosion may occur owing to minor dechlorination, a combination of only polyurethane and isocyanate may be used.

In the magnetic tape of the type, the amount of the binder, the proportion of the vinyl chloride-based resin in the binder, the amount of the polyurethane resin, the polyisocyanate resin and other resins, the molecular weight and the polar group content of the resins constituting the magnetic layer, as well as various physical properties of the resins mentioned above may be optionally varied between the non-magnetic layer and the magnetic layer, and they are rather optimized in the respective layers. For this, employable are any known techniques relating to multi-layered magnetic layers. For example, when the binder amount is varied in each layer, it is effective to increase the binder amount in the magnetic layer so as to reduce the surface abrasion of the magnetic layer. In order to improve the head touch of the tape to heads, the binder amount in the non-magnetic layer may be increased so as to soften the tape.

<Ferromagnetic Powder>

The ferromagnetic powder to be used in the magnetic layer is preferably a ferromagnetic alloy powder comprising a principal component of α-Fe. The ferromagnetic powder may contain any other atoms such as Al, Si, S, Sc, Ca, Ti, V, Cr, Cu, Y, Mo, Rh, Pd, Ag, Sn, Sb, Te, Ba, Ta, W, Re, Au, Hg, Pb, Bi, La, Ce, Pr, Nd, P, Co, Mn, Zn, Ni, Sr and B, in addition to the predetermined atom. In particular, the powder preferably contains at least one of Al, Si, Ca, Y, Ba, La, Nd, Co, Ni and B, in addition to α-Fe, more preferably at least one of Co, Y and Al.

The ferromagnetic alloy powder may contain a small amount of a hydroxide or an oxide. The ferromagnetic alloy powder for use herein may be any one produced according to any known method. For producing it, for example, the following methods may be mentioned: A method of reducing a composite organic acid salt (principally oxalate) with a reducing vapor such as hydrogen; a method of reducing iron oxide with a reducing vapor such as hydrogen to obtain Fe or Fe—Co particles; a method of pyrolyzing a metal carbonyl compound; a method of adding a reducing agent such as sodium borohydride, hypophosphite or hydrazine to an aqueous solution of a ferromagnetic metal so as to reduce the metal; a method of vaporizing a metal in a low-pressure inert gas to obtain a fine powder of the metal. Thus obtained, the ferromagnetic alloy powder may be subjected to known slow oxidation, for example, according to a method of dipping it in an organic solvent and then drying it; or a method of dipping it in an organic solvent, then introducing oxygen-containing gas into it so as to form an oxide film on the surface of the particles and thereafter drying the particles; or a method of forming an oxide film on the surface of the particles by controlling the partial pressure of the oxygen gas and the inert gas applied thereto, not using an organic solvent. The ferromagnetic alloy powder thus processed in any of these methods may be used herein.

A hexagonal-system ferrite powder may also be used for the ferromagnetic powder to be in the magnetic layer. The hexagonal-system ferrite includes, for example, barium ferrite, strontium ferrite, lead ferrite, calcium ferrite, and their substituted derivatives such as Co-substituted derivatives. Concretely, there are mentioned magnetoplumbite-type barium ferrite and strontium ferrite, spinel-coated magnetoplumbite-type ferrite, partially spinel phase-containing magnetoplumbite-type barium ferrite and strontium ferrite. They may contain any other atoms such as Al, Si, S, Sc, Ti, V, Cr, Cu, Y, Mo, Rh, Pd, Ag, Sn, Sb, Te, Ba, Ta, W, Re, Au, Hg, Pb, Bi, La, Ce, Pr, Nd, P, Co, Mn, Zn, Ni, Sr, B, Ge and Nb, in addition to the predetermined atoms. In general, substances with elements such as Co—Ti, Co—Ti—Zr, Co—Ti—Zn, Ni—Ti—Zn, Nb—Zn—Co, Sb—Zn—Co or Nb—Zn added thereto may be used.

(Non-Magnetic Layer)

The inorganic powder to be sued in the non-magnetic layer is a non-magnetic powder and may be selected, for example, from inorganic compounds such as metal oxides, metal carbonates, metal sulfates, metal nitrides, metal carbides, metal sulfides. Carbon black may be added to the non-magnetic layer so as to attain known effects of reducing the surface resistivity Rs, reducing the light transmittance and obtaining a desired micro-Vickers hardness. When carbon black is added to the lower layer, then the layer may be effective for storing lubricant. Regarding its type, carbon black usable herein may be any of furnace black for rubber, thermal black for rubber, black for color, and acetylene black. Depending on the desired effect thereof, carbon black to be in the lower layer must optimize the characteristics mentioned below. When combined in the layer, carbon black may exhibit its effect. In addition, the non-magnetic layer may contain an organic powder depending on its object. Known techniques relating to the magnetic layer may apply to the lubricant, the dispersant, the additive, the solvent and the dispersion method in the non-magnetic layer.

[Additive]

The additives that may be in the magnetic layer and the non-magnetic layer may be those having a head-cleaning effect, a lubricating effect, an antistatic effect, a dispersing effect and a plasticizing effect. Concretely, those described in WO 98/35345 may be used herein.

For the lubricant, for example, herein usable are monobasic fatty acids having from 10 to 24 carbon atoms, and their metal salts (e.g., with Li, Na, K, Cu); monofatty acid esters, difatty acid esters or trifatty acid esters of monobasic fatty acids having from 10 to 24 carbon atoms and at least any one of mono, di, tri, tetra, penta or hexa-alcohols having from 2 to 12 carbon atoms; fatty acid esters of monoalkyl ethers of alkylene oxide polymers; and fatty acid amides having from 8 to 22 carbon atoms. The fatty acids and alcohols may contain unsaturated bond and may be branched.

Specific examples of the fatty acids are capric acid, caprylic acid, lauric acid, myristic acid, palmitic acid, stearic acid, behenic acid, oleic acid, elaidic acid, linolic acid, linolenic acid, isostearic acid. The esters include butyl stearate, octyl stearate, amyl stearate, isooctyl stearate, butyl myristate, octyl myristate, butoxyethyl stearate, butoxydiethyl stearate, 2-ethylhexyl stearate, 2-octyldodecyl palmitate, 2-hexyldodecyl palmitate, isohexadecyl stearate, oleyloleate, dodecyl stearate, tridecylstearate, oleylerucate, neopentylglycol didecanoate, ethylene glycol dioleate.

(Back Layer)

Preferably, the back layer contains carbon black and an inorganic powder. Regarding the binder and various additives to the back layer, referred to are those mentioned hereinabove for the magnetic layer and the non-magnetic layer. The thickness of the back layer is preferably from 0.1 to 1.0 μm, more preferably from 0.4 to 0.6 μm.

(Support)

The support for the magnetic tape is preferably a non-magnetic flexible support. For this, usable are any known films of polyesters such as polyethylene terephthalate, polyethylene naphthalate; as well as polyolefins, cellulose triacetate, polycarbonates, aromatic or aliphatic polyamides, polyimides, polyamidimides, polysulfones, polyaramids, and polybenzoxazole of those, preferred are polyethylene terephthalate films and polyimide films. The support may be previously processed for corona discharge treatment, plasma treatment, adhesiveness improvement treatment, thermal treatment or dust removal treatment.

Preferably, the support has an elastic modulus in the machine direction of from 3.5 to 20 GPa, and an elastic modulus in the cross direction of from 3.5 to 20 GPa. More preferably, the elastic modulus of the support is from 4 to 15 in both the machine direction and the cross direction.

(Production Method)

The magnetic layer and the non-magnetic layer may be formed by dissolving or dispersing the above-mentioned components in a solvent to prepare coating compositions for these, and applying the compositions in order on a support (web). The method may be either a wet-on-wet system where the magnetic layer is formed while the underlying non-magnetic layer is still wet, or a wet-on-dry system where the magnetic layer is formed after the underlying non-magnetic layer is dried. Thus coated and dried, the web is suitably oriented, calendered and slit.

[Data-Recording Magnetic Tape]

The data-recording magnetic tape for use herein comprises a magnetic layer formed on a non-magnetic support, and optionally has aback layer. One preferred embodiment of the tape comprises a non-magnetic lower layer and a magnetic upper layer formed on a support having a thickness of from 2 to 9 μm, and has a back layer formed on the opposite side thereto. The constitutive elements of the magnetic tape are suitable to high-density recording, and the magnetic tapes described in JP-A2001-250219 and 2002-251710 are preferred examples for use herein.

[Magnetic Tape Cartridge]

The magnetic tape cartridge of the invention is so designed that a magnetic tape is wound up around one or more reels rotatably housed in the cartridge case, and this is characterized in that the leader tape that is bonded to the top end of the magnetic tape and is let out toward a magnetic recording and reproduction device while leading the magnetic tape is the leader tape of the invention.

[Magnetic Recording and Reproduction Device, and Magnetic Recording and Reproduction Method]

The leader tape of the invention exhibits its effect when used in a magnetic recording and reproduction device where the line recording density is at least 100 kfci and the difference between the recording track width and the reproduction track width is from 0 to 16 μm, and its effect is more remarkable when it is used in a magnetic recording and reproduction device where the difference between the recording track width and the reproduction track width is at most 10 μm.

Preferably, the thickness of the leader tape is at most 5 times that of the magnetic tape, more preferably at most 3 times, even more preferably at most 2 times.

Also preferably, the length of the leader tape is not shorter than the length corresponding to at least 3 windings of the drive reel in the magnetic recording and reproduction device, plus the tape running route length from the mouth of the cartridge case to the drive reel.

One embodiment of the magnetic recording and reproduction device and the magnetic recording and reproduction method of the invention is described in detail with reference to the drawings attached hereto. Of the drawings that are referred to herein, FIG. 1 is a constitutional view conceptually showing one embodiment of the recording and reproduction device of the invention; FIG. 2 is a perspective exploded view showing the magnetic tape cartridge used in the magnetic recording and reproduction device; FIG. 3A is a perspective view of the drive reel (take-up reel) used in the magnetic recording and reproduction device; FIG. 3B is a partly-enlarged cross-sectional view of FIG. 3A cut along the IIIB-IIIB line. The magnetic recording and reproduction device of this embodiment comprises a magnetic tape cartridge with a magnetic tape wound up around one cartridge reel (let-off reel) and a magnetic tape drive (tape drive) loaded with the magnetic tape cartridge, and this is used in the magnetic recording and reproduction method described hereinunder.

As in FIG. 1, the magnetic recording and reproduction device 1 comprises a magnetic tape cartridge 10 and a magnetic tape drive 20. In the magnetic recording and reproduction device 1 of the type, the magnetic tape MT wound up in the magnetic tape cartridge 10 is let off and taken by the drive reel of the magnetic tape drive 20 that serves as a tape receiver, or the magnetic tape MT thus wound up around the drive reel 20 is unwound toward the cartridge reel (let-off reel) 11, whereby information is recorded on the magnetic tape MT or the information thus recorded on the magnetic tape MT is reproduced.

As in FIG. 2, the magnetic tape cartridge 10 satisfies the LTO Standard, and this has a cartridge case 2 divided into a lower half 2B and an upper half 2A. Inside it, the cartridge case 2 houses a single cartridge reel 11 around which a magnetic tape MT is wound up; a reel lock and a compression coil spring 5 for keeping the rotation of the cartridge reel 11 locked; a release pad 6 for releasing the locked condition of the cartridge reel 11; a slide door 2D for opening and closing the magnetic tape let-off mouth 2C formed on one face of the cartridge case 2 to extend to both the lower half 2B and the upper half 2A; a twisted coil spring 7 for forcedly pushing the slide door 2D toward the closing position of the magnetic tape let-off mouth 2C; a miserasure preventing claw 8; and a leader pin rack 9 formed near the magnetic tape let-off mouth 2C. A leader tape LT is bonded to the top end of the magnetic tape MT. The magnetic tape MT in FIG. 2 is the leader tape LT.

The magnetic tape cartridge 10 is loaded in the magnetic tape drive 20, as in FIG. 1, and the leader tape LT is let out by the leader block 31 which will be described hereinunder, and the leader block 31 is fitted into the recess 23 formed in the core 22 of the drive reel 21 in the magnetic tape drive 20. Accordingly, the leader tape TL from the magnetic tape cartridge 10 may be thereby wound up around the core 22 of the drive reel 21.

The leader tape LT and the magnetic tape MT used in the magnetic tape cartridge 10 of this embodiment are described in detail.

The leader tape LT is formed long, and in this embodiment, its length is enough to correspond to at least 3 windings around the core 22 of the drive reel 21 in the magnetic tape drive 20. The leader tape LT preferably has a length of from 0.5 to 5.0 m, more preferably 0.9 m.

Next described is the magnetic tape drive 20.

The magnetic tape drive 20 comprises a spindle 24, a spindle drive unit 25 for driving the spindle 24, a magnetic head H, a drive reel 21, a take-up reel drive unit 26 for driving the drive reel 21, and a control unit 27, as in FIG. 1.

In addition, the magnetic tape drive 20 is provided with a leader block 31 capable of engaging with the leader pin (see FIG. 2) disposed at the top end of the leader tape LT from the magnetic tape cartridge 10, and the leader block 31 is moved toward the magnetic tape cartridge 10 by a lead-off mechanism (not shown) including a lead-off guide 32 or the like.

When data are recorded/reproduced on/from the magnetic tape MT, the spindle drive unit 25 and the take-up reel drive unit 26 act to rotate and drive the spindle 24 and the drive reel 21, whereby the magnetic tape MT is moved.

The drive reel 21 is so designed that the upper face of the lower flange 21 a has radial grooves 21 b formed at regular intervals, as in FIGS. 3A and 3B. The grooves 21 b function as discharge paths for discharging the air that may enter the drive reel 21 while the magnetic tape MT is wound up around it.

The action of the magnetic tape drive 20 is described.

When the magnetic tape cartridge 10 is set in the magnetic tape drive 20 as in FIG. 1, then the lead-off guide 32 (see FIG. 2) acts to lead out the leader pin 30 and move it to the drive reel 21 via the magnetic head H, and the leader block 31 is thereby fitted into the recess 23 of the core 22 of the drive reel 21. The recess 23 is provided with an anchor part (not shown) that engages with the leader block 31 to thereby prevent the leader block 31 from jumping out of the recess 23.

With that, the spindle drive unit 25 and the take-up reel drive unit 26 are driven while controlled by the control unit 27, and the spindle 24 and the drive reel 21 are rotated in the same direction so that the leader tape LT and the magnetic tape MT are moved toward the drive reel 21 from the cartridge reel 11. Accordingly, the leader tape LT is wound up around the drive reel 21, and then the magnetic tape MT is wound up around the drive reel 21, whereupon information is recorded on the magnetic tape MT or the information recorded on the magnetic tape MT is reproduced by the action of the magnetic head H.

When the magnetic tape MT is rewound around the cartridge reel 11, the spindle 24 and the drive reel 21 are rotated and driven in the direction opposite to the above, whereby the magnetic tape MT is moved toward the cartridge reel 11. Also in the rewinding operation, information recording on the magnetic tape MT or information reproduction from the magnetic tape MT may be attained by the magnetic head H.

In the magnetic recording and reproduction device 1 of the type, the magnetic tape MT is generally kept wound in the magnetic cartridge 10 in many cases, but in some use embodiment, it may be kept wound up around the drive reel 21 in the magnetic tape drive 20 for a long period of time. In some such use embodiment, the usefulness of preventing leader block embossment is extremely great, and the leader tape and the magnetic tape cartridge employed in the magnetic recording and reproduction device 1 of this embodiment and the magnetic recording and reproduction method for the device 1 are favorable for the case. Specifically, when the magnetic tape MT is wound up around the drive reel 21 of the magnetic tape drive 20 from the magnetic tape cartridge 10, the leader block 31 that acts to lead the magnetic tape MT out of the magnetic tape cartridge 10 is fitted into the core 22 of the drive reel 21, but depending on the dimensional accuracy of the leader block 31, the leader block 31 may protrude (as level difference) from the edge face of the core 22. In such a case, when a related art leader tape is wound up around the drive reel 21, then the level difference may be embossed to the magnetic tape MT and the distance between the magnetic head and the magnetic layer may be enlarged, therefore causing some problems of recording failure and information loss in the magnetic tape MT.

Contrary to this, in the magnetic recording and reproduction method of the invention, the level difference can be well absorbed by the leader tape LT, and even when the magnetic recording and reproduction device 1 is used, in which the line recording density is at least 100 kfci and the difference between the recording track width and the reproduction track width is from 0 to 16 μm, the method of the invention enjoys the advantage in that it can evade the problems of recording failure and information loss in the magnetic tape MT.

EXAMPLES

The invention is described in detail with reference to the following Examples, to which, however, the invention should not be limited.

Example 1

In the Examples, “part” is by weight.

Formation of Leader Tape:

<Preparation of Coating Compositions> Coating Composition for upper layer: Ferromagnetic metal powder  100 parts coercive force Hc: 191 kA/m (2400 Oe) specific surface area by BET method: 62 m²/g crystallite size: 110 angstroms saturation magnetization σs: 117 A · m²/kg mean major axis length: 45 nm mean acicular ratio: 5 pH: 9.3 Co/Fe: 25 atm. % Al/Fe: 7 atm. % Y/Fe: 12 atm. % Vinyl chloride-based copolymer (Nippon Zeon's MR-100)   5 parts (—SO₃Na content: 5 × 10⁻⁶ eq/g, degree of polymerization: 350), epoxy content: 3.5 mas. % as monomer unit) Polyester-polyurethane resin   12 parts (neopentylglycol/caprolactone polyol/MDI = 0.9/2.6/1 by weight, —SO₃Na content: 1 × 10⁻⁴ eq/g) α-alumina (mean particle size: 0.3 μm)   10 parts Carbon black (mean particle size: 0.10 μm)   1 part Butyl stearate  1.5 parts Stearic acid  0.5 parts Methyl ethyl ketone  150 parts Cyclohexanone   50 parts Toluene   40 parts

Coating Composition for under layer: Non-magnetic powder, acicular α-iron oxide   80 parts specific surface area by BET method: 58 m²/g mean major axis length: 0.15 μm acicular ratio: 7.5 Carbon black   20 parts mean primary particle size: 16 nm DBP oil absorption: 80 ml/100 g pH: 8.0 specific surface area by BET method: 250 m²/g Vinyl chloride-based polymer   12 parts Nippon Zeon's MR-100 Polyester-polyurethane resin   5 parts (neopentylglycol/caprolactone polyol/MDI = 0.9/2.6/1 by weight, —SO₃Na content: 1 × 10⁻⁴ eq/g) Butyl stearate 1.06 parts Stearic acid 1.18 parts Methyl ethyl ketone  150 parts Cyclohexanone   50 parts Toluene   40 parts

The constitutive components of the upper layer coating composition and those of the lower layer coating composition were separately kneaded in a continuous kneader and then dispersed by the use of a sand mill. 5 parts of polyisocyanate (Nippon Polyurethane's Coronate L) was added to each of the resulting dispersions, and 40 parts of methyl ethyl ketone was added to each of them. The dispersions were filtered through a filter membrane having a mean pore size of 1 μm, and the upper layer coating composition and the lower layer coating composition were thus obtained. Coating Composition for back layer formation: Particulate carbon black  100 parts (Cabot's BP-800, mean particle size: 17 nm) Coarse carbon black  10 parts (Carncalp's thermal black, mean particle size: 270 nm) α-alumina (hard inorganic powder)   5 parts (mean particle size: 200 nm, Mohs' hardness: 9) Nitrocellulose resin  140 parts Polyurethane resin  15 parts Polyester resin   5 parts Dispersant: copper oleate   5 parts Copper phthalocyanine   5 parts Barium sulfate (precipitating)   5 parts (BF-1, mean particle size: 50 nm, Mohs' hardness: 3, by Sakai Kagaku Kogyo) Methyl ethyl ketone 1200 parts Butyl acetate  300 parts Toluene  600 parts

The constitutive components of the back layer coating composition were kneaded in a continuous kneader and then dispersed by the use of a sand mill. 40 parts of polyisocyanate (Nippon Polyurethane's Coronate L) and 1000 parts of methyl ethyl ketone were added to the resulting dispersion, and this was filtered through a filter membrane having a mean pore size of 1 μm to prepare a back layer coating composition.

Formation of Leader Tape:

The upper layer coating composition and the lower layer coating composition thus obtained in the above were applied at the same time to a long-size polyethylene terephthalate (PET) support (thickness: 14.5 μm, Young's modulus in MD direction: 500 kg/mm² (4.9 GPa), Young's modulus in TD direction: 500 kg/mm² (4.9 GPa), center line average roughness Ra of the upper layer-coated face: 35 nm, Ra of the back layer-coated face: 36 nm) in a mode of simultaneous coating to form an upper layer and a lower layer so that they could have a dry thickness of 0.1 μm and 1.4 μm, respectively. Next, while the upper layer was still wet, this was oriented by the use of a cobalt magnet having a magnetic force of 300 mT and a solenoid having a magnetic force of 150 mT. Next, this was dried, and the upper layer was thus formed.

Next, on the other face of the support (opposite side to the upper layer), the back layer coating composition was applied to form a back layer so that it could have a dry thickness of 0.5 μm. Then, this was dried and the back layer was formed. Accordingly, a leader tape roll was thus obtained, having the upper layer on one face of the support and having the back layer on the other face thereof.

Further, after heat-treated, the roll was calendered by passing it through a 7-stage calendering machine (temperature: 90° C., linear pressure: 300 kg/cm (294 kN/m)) that comprises a heating metal roll and an elastic roll formed by covering a core metal with a thermosetting resin.

The resulting roll was further heated at 50° C. for 48 hours. Next, this was cut into pieces having a width of ½ inches to obtain leader tapes. The overall thickness of the leader tape was 16.5 μm, and Ra of the magnetic face thereof was 25 nm and Ra of the back face thereof was 30 nm.

[Data Recording Magnetic Tape]

The upper and lower layer coating compositions and the back layer coating composition used for the leader tape as above were applied to a polyethylene naphthalate (PEN) support having Ra of the face thereof to be coated with a magnetic layer of 3 nm and having a thickness of 5.2 μm. Concretely, the coating compositions were applied to the support at the same time in a mode of simultaneous coating to form a non-magnetic lower layer having a thickness of 1.0 μm and a magnetic upper layer having a thickness of 0.1 μm. Then, this was subjected to the same magnetic field orientation as that for the above-mentioned leader tape.

Next, a back layer was formed on it so as to have a dry thickness of 0.5 μm. Also like the leader tape as above, this was worked into data recording magnetic tapes having a width of ½ inches.

[Construction of Magnetic Tape Cartridge]

The ½-inch wide magnetic tape obtained in the above was used as a leader tape, and this was connected to the data recording magnetic tape to construct a magnetic tape cartridge. In this, 830 m of the magnetic tape was wound up.

Example 2

In the formation of a leader tape as in Example 1, herein used was a PET support of which one face to be coated with multi-layers had a center line average roughness Ra of 10 nm.

Examples 3 to 6

In the formation of a leader tape as in Example 1, the thickness of the PET support and Ra of the support were varied as in Table 1, and the others were the same as in Example 1 to construct magnetic tape cartridges of the invention.

Comparative Example 1

In the formation of a leader tape as in Example 1, Ra of the support was controlled like in the Example.

Comparative Example 2

In the formation of a leader tape as in Example 1, only the upper layer having a thickness of 1.5 μm was formed in a mode of single-layer formation, and the others were the same as in Example 1 to construct a magnetic tape cartridge.

[Evaluation of Magnetic Tape Cartridge]

Thus obtained, the magnetic tape cartridge were tested under the test condition mentioned below and evaluated.

(Leader block embossment Test)

The magnetic tape cartridge was set in an LTO-modified drive, in which a signal of a line recording density of 150 kfci was recorded on the recording tape at a recording track width of 10 μm and a reproduction track width of 4.5 μm, and all its length was wound up around the drive reel under a tension of 0.8 N. In that condition, every drive stored at 50° C. for 12 hours. After the storage, the tape was reproduced, and the error rate at the tape start end was determined and the length of the tape having leader block embossment thereto (embossment length: distance from the leader tape bonding part) was visually measured. The error rate expression “1.5E-07” means “1.5×10⁻⁷” (the same shall apply to the others).

In Example 6, the head design was varied, and the recording track width, the reproduction track width and the line recording density were changed as in Table 1. In that condition, the tape was subjected to the same embossment test. AT indicates the difference between the recording track width and the reproduction track width. TABLE 1 Comparative Comparative Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 1 Example 2 Leader Tape magnetic nm 25 11 57 26 26 26 5 70 layer Ra back nm 30 13 55 29 29 29 8 68 layer Ra thickness μm 16.5 16.5 16.5 6.5 29 16.5 16.5 16.5 Support thickness μm 14.5 14.5 14.5 4.5 17.0 14.5 14.5 14.5 Ra nm 35 10 70 35 35 35 3 90 Magnetic line kfci 150 150 150 150 150 100 150 150 Recording recording and density Reproduction ΔT μm 8.0 8.0 8.0 8.0 8.0 15.0 80 8.0 Device Evaluation error 1.5E−07 2.5E−06 1.5E−07 6.5E−07 1.0E−07 1.0E−07 3.0E−03 head broken rate embossment m 1.1 4.5 0.6 2.5 0.9 1.2 45 0.5 length

It is understood that in the Examples of the invention where the magnetic recording and reproduction device used is so controlled that the line recoding density is 150 kfci and Δt is 8.0 μm, the error rate is smaller and the embossment length is shorter than those in the Comparative Examples.

This application is based on Japanese Patent application JP 2004-091822, filed Mar. 26, 2004, the entire content of which is hereby incorporated by reference. This claim for priority benefit is being filed concurrently with the filing of this application.

FIG. 1:

-   1 MAGNETIC RECORDING AND REPRODUCTION DEVICE -   10 MAGNETIC TAPE CARTRIDGE -   24 SPINDLE -   20 MAGNETIC TAPE DRIVE -   11 CARTRIDGE REEL -   H MAGNETIC HEAD -   MT MAGNETIC TAPE -   31 LEADER BLOCK -   21 DRIVE REEL -   25 SPINDLE DRIVE UNIT -   27 CONTROL UNIT -   26 TAKE-UP REEL DRIVE UNIT

FIG. 2:

-   10 MAGNETIC TAPE CARTRIDGE -   2 CARTRIDGE CASE -   2A UPPER HALF -   2B LOWER HALF -   11 CARTRIDGE REEL -   MT MAGNETIC TAPE (LT LEADER TAPE) -   30 LEADER PIN -   31 LEADER BLOCK

FIGS. 3A AND 3B:

-   21 DRIVE REEL (TAKE-UP REEL) -   21A FLANGE -   21B GROOVE -   21 DRIVE REEL (TAKE-UP REEL) -   21B GROOVE -   21A FLANGE

FIGS. 4A TO 4C:

-   41 CORE -   40A END FACE -   LT LEADER TAPE -   41 CORE -   40A END FACE -   LT LEADER TAPE -   LT LEADER TAPE -   41 CORE -   MT MAGNETIC TAPE 

1. A leader tape having, on at least one face of a support, a coating layer that contains a powder and a binder, wherein a center line average roughness (Ra) of at least one face of the leader tape is from 10 to 60 nm, and the leader tape is used in a magnetic recording and reproduction device where a line recording density is at least 100 kfci, and a difference between a recording track width and a reproduction track width is from 0 to 16 μm.
 2. The leader tape according to claim 1, which has a thickness of from 5 to 20 μm.
 3. A magnetic tape cartridge where a magnetic tape is wound up around one or more reels rotatably housed in the cartridge case, in which the leader tape that is bonded to the top end of the magnetic tape and is let out toward a magnetic recording and reproduction device while leading the magnetic tape is the leader tape of claim
 1. 4. A magnetic recording and reproduction method, which performs recording and reproduction by using the magnetic tape cartridge of claim 3 in the magnetic recording and reproduction device in claim
 1. 5. A combination of a leader tape and a magnetic recording and reproduction device, wherein the leader tape comprises: a support; and a coating layer that contains a powder and a binder on at least one face of the support, at least one face of the leader tape having a center line average height of from 10 to 60 nm, and the magnetic recording and reproduction device has a line recording density of 100 kfci or more, and a difference between a recording track width and a reproduction track width of from 0 to 16 μm.
 6. The combination according to claim 5, wherein the line recording density is 130 kfci or more.
 7. The combination accroding to claim 5, wherein the line recording density is 150 kfci or more.
 8. The combination accroding to claim 5, wherein the difference is 4 to 16 μm.
 9. The combination accroding to claim 5, wherein the difference is 4 to 10 μm.
 10. The combination accroding to claim 5, wherein the coating layer further contains a lubricant.
 11. The combination according to claim 5, wherein the leader tape has a thickness of from 5 to 20 μm.
 12. The combination according to claim 5, wherein the leader tape has a thickness of from 8 to 18 μm.
 13. The combination according to claim 5, wherein the leader tape has a surface resistivity of at most 10¹⁰ Ω/sq.
 14. The combination according to claim 5, wherein the leader tape has a surface resistivity of at most 10⁹ Ω/sq. 